Prefabricated Custom Patios and Method

ABSTRACT

A custom patio fabricated by constructing, at a first location, a patio customized for a second location, and cutting the patio into sections. The patio preferably is customized for the second location in one or more of size, shape, color, and surface pattern. Preferably, the patio is constructed at the first location under controlled conditions. The conditions can be controlled by constructing the patio indoors, for example for temperature, humidity, or temperature and humidity, or can be controlled by constructing the patio outdoors but only under certain weather conditions. The conditions also can include controlling a grade of a base on which the patio is constructed to be level, as well as other conditions.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/970,053 filed Sep. 5, 2007, titled “Prefabricated Custom Patios,” inthe name of the same inventor, attorney docket no. BBC-001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to prefabricated custom patios and methods offabricating and installing such patios.

2. Description of the Related Art

Custom patios are well known. However, these patios are usuallyexpensive to design and to install.

In addition, custom patios typically are poured and installed on site(e.g., at a customer's home). As a result, environmental conditionssometimes cannot be controlled during installation. Wet ground, poorweather at the time of installation, and the like can affect the qualityof a patio. As a result, custom patios sometimes are of relatively poorquality despite their cost.

Furthermore, properly installed patios slope slightly away from astructure such as a house so that water drains away from the structure.The patios are therefore poured with a sloping top surface, whichresults in different thicknesses across the patio. As a result, anupslope part of the patio should be thicker than required for durabilityso that the downslope part is thick enough. If this is done, excessmaterial (e.g., concrete) can be used, resulting in increased cost. Ifthis is not done, the downslope part of the patio can have inadequatestrength, resulting in poor durability.

SUMMARY OF THE INVENTION

The invention provides techniques for fabricating and installing custompatios that address the foregoing concerns.

In some embodiments, a custom patio is fabricated by constructing, at afirst location, a patio customized for a second location, and cuttingthe patio into sections.

The patio preferably is customized for the second location in one ormore of size, shape, color, and surface pattern.

Preferably, the patio is constructed at the first location undercontrolled conditions. The conditions can be controlled by constructingthe patio indoors, for example for temperature, humidity, or temperatureand humidity, or can be controlled by constructing the patio outdoorsbut only under certain weather conditions. The conditions also caninclude controlling a grade of a base on which the patio is constructedto be level, as well as other conditions.

The patio preferably is further fabricated by installing a level gravelbase, covering the gravel base with plastic to create a flat levelsurface, constructing a form on the base, placing a wire mesh on thebase inside the form, pouring concrete into the form, allowing theconcrete to cure, and adding a sealant to the patio's surface. One ormore colors, surface patterns, or colors and surface patterns can beadded to the patio.

Preferably, the sections are transported to and installed at the secondlocation. Transporting the sections to the second location can alsoinclude adding numbers to the sections, stacking the sections separatedby a protective material, and transporting the stacked sections.Installing the sections can include preparing the second location forinstallation of the patio, and assembling the sections at the secondlocation according to the numbers.

The invention encompasses patios fabricated as described above, as wellas method of fabricating such patios.

This brief summary has been provided so that the nature of the inventionmay be understood quickly. A more complete understanding of theinvention may be obtained by reference to the following description ofthe preferred embodiments thereof in connection with the attacheddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flowchart describing fabrication of custom patiosaccording to some embodiments of the invention.

FIGS. 2 to 9 illustrate an example of a patio at various steps duringthe fabrication of custom patios according to some embodiments of theinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

U.S. Provisional Application No. 60/970,053 filed Sep. 5, 2007, titled“Prefabricated Custom Patios,” in the name of the same inventor,attorney docket no. BBC-001, is hereby incorporated by reference as iffully set forth herein.

FIG. 1 shows a flowchart describing fabrication of custom patiosaccording to some embodiments of the invention.

In some embodiments, the term “custom” refers to customized for a singlelocation. In other words, a custom patio could be a “one-off” patio thathas a particular size, shape, pattern, coloration, etc. for a singlelocation. In other embodiments, the term “custom” refers to customizedfor a particular class or group of locations. In other words, a custompatio could be a copy of another custom patio already installed atanother location, possibly with some variances. However, “custom”precludes patios mass produced without consideration for theirinstallation location.

Briefly, one embodiment of a method of fabricating a custom patioincludes step 10 of constructing, at a first location, a patiocustomized for a second location, and step 20 of cutting the patio intosections. Fabrication can further include step 30 of transporting thesections to the second location, and step 40 of installing the sectionsat the second location to form the custom patio. Possiblecharacteristics and sub-steps for these steps are further describedbelow.

Preferably, step 10 includes controlling conditions 11 under whichconstruction occurs. For example, if construction occurs indoors,temperature, humidity, and/or other conditions can be controlled to helpensure good quality. As another example, if construction occursoutdoors, construction could be performed during good weatherconditions. In particular, because the patio is constructed at aseparate location from where it is going to be installed, theconstruction can occur at any time, so construction can be delayedduring bad weather such as cold temperature, high wind, rain, or thelike. Other types of control of construction conditions can be used.

Steps 12 to 19 are possible sub-steps for step 10 of constructing, at afirst location, a patio customized for a second location. FIGS. 2 to 5illustrate an example of a patio at very stages during these sub-steps.The invention is not limited to these steps or these examples.

At step 12, a level gravel base is installed. This base preferably isgraded and checked with a carpenter's (or other) level to ensure that itis close to true level. Even though the patio preferably will beinstalled in later steps with a slight slope away from any adjacentstructure such as a house, the patio preferably is constructed at thefirst location on a level base. This helps to ensure uniformity andquality of the resulting patio.

In alternative embodiments, a different type of base such as a concretefloor or indoor workspace floor can be used. Other options for the baseexist.

At step 13, the base is covered with plastic, thereby providing a flatlevel surface for constructing the patio. Alternatively, some othermaterial could be used. Other options exist to provide a flat levelsurface.

At step 14, a form for the patio is constructed on top of the plastic.The form can be made of any suitable material, for example wood, metal,plastic, or the like. This form preferably is customized in terms ofsize, shape, or the like for installation at the second location. FIG. 2shows such a form 50 on top of plastic 51 that covers a level base (notshown).

At step 15, an optional wire mesh is placed inside the form. This meshadds strength to the resulting patio. FIG. 3 shows such a wire mesh 52.Other types of strengthening can be used, for use of specializedmaterials in the patio. Alternatively, such strengthening can beomitted.

At steps 16 and 17, concrete or some other suitable patio material ispoured into the form and allowed to cure (if necessary). Sealantpreferably is added in step 18.

Further customization can occur in step 19, for example addition ofcolor(s), engraved or surface pattern(s), and the like. FIG. 4 shows apatio 54 customized with an abstract pattern. Other types ofcustomization can occur before or after this step.

As mentioned above, the patio is cut into section in step 20. FIG. 5illustrates patio 54 cut into such sections as indicated by grid lines55. The patio can be cut into any suitably sized and shaped sections.Preferably, the sections are small enough to be handled easily whilebeing large enough to permit relatively quick assembly. Sections ofabout 3′6″ square have been found to work well, although smaller orlarger sections also could be cut.

Preferably, square or rectangular sections are cut because of the easeof cutting a patio into these shapes. However, the sections do not haveto be of any particular shape and do not have to be all of the sameshape. For example, sometimes the selected pattern of sections couldresult in a small section that could be easily lost, harder to place, orotherwise inconvenient. In some embodiments, such sections might not becut out completely, resulting in one or more irregularly shaped sectionssuch as section 56 in FIG. 5. Alternatively, the patio could be cut intosections without worrying about such concerns.

The sections preferably are numbered in step 21. This numbering can beused to help facilitate assembly, as discussed below.

The sections also could be modified in other ways to assist withassembly or to enhance aesthetics. For example, holes, dowels, biscuits,shaped edges, or the like can be added to help secure the sections toeach other during assembly. The sections also could be shaped with edgesthat lock together. For another example, the sections could be cut alonglines of an engraved or surface pattern that is present on the patio,thereby hiding the cuts and resulting seams when the sections are laterassembled.

At this point, that patio can be considered to be fabricated.Alternatively, the patio could be considered to be fabricated afterinstallation, which preferably involves step 30 of transporting thesections to the second location and step 40 of installing the sectionsat the second location.

Step 30 preferably includes steps 31 of stacking the sections and step32 of transporting the sections to the second location. The stackedsections preferably are separated by protective materials such as foam,Styrofoam, blankets, plastic, or any other material that protects thesections from each other during transportation. FIG. 6 shows an exampleof stacked patio section 57 separated by protective layers 58.

Step 40 preferably includes step 41 of preparing the second location forinstallation of the patio. Preparation preferably is performed as withstandard patios, for example leveling, grading with a slope away from astructure, installation of plastic to inhibit growth of weeds throughthe patio, and the like.

Step 40 also preferably includes step 42 of assembling the sectionaccording to their numbering. Use of the numbers (if present) duringassembly helps prevent having to piece the sections together like apuzzle. In some embodiments, sections of a patio can include holes,dowels, biscuits, shaped edges, or the like to secure them to eachother. The sections also could be shaped with edges that lock together.Adhesives, brackets, and/or any other suitable joining materials andtechniques also can be used to join the sections. Alternatively, thesections could simply be placed next to each other during assembly.

FIG. 7 shows a structure 59 prepared for a patio with graded location60. FIG. 8 shows a partially installed patio 61, and FIG. 9 shows acompletely installed patio 62 at this location.

In the foregoing description, a custom patio is constructed at a firstlocation, cut into sections, transported to a second location, and theninstalled. These locations could be separated from each other bysignificant distance, for example requiring transportation of thesections from a factory to a house or other structure. Alternatively,the locations could be on a single property, with transportationoccurring by simple walking and carrying. In this later example,benefits can still accrue from being able to construct the patio on alevel base and not having a structure in the way of constructing thepatio. In such a circumstance, the various steps shown in FIG. 1 mightbe performed in an overlapping manner. Other ways of implementing theinvention and its steps are also possible, possibly in different orders.

Alternative Embodiments

The invention is in no way limited to the specifics of any particularembodiments and examples disclosed herein. For example, the terms“preferably,” “preferred embodiment,” “one embodiment,” “someembodiments,” “alternative embodiment,” “alternatively,” “for example,”“can,” and the like denote features that are preferable but notnecessarily essential to include in embodiments of the invention. Theterms “comprising” or “including” mean that other elements and/or stepscan be added without departing from the invention. Many other variationsare possible which remain within the content, scope and spirit of theinvention, and these variations would become clear to those skilled inthe art after perusal of this application.

1. A method of fabricating a custom patio, comprising the steps of:constructing, at a first location, a patio customized for a secondlocation; and cutting the patio into sections.
 2. A method as in claim1, wherein the patio is customized for the second location in one ormore of size, shape, color, and surface pattern.
 3. A method as in claim1, wherein the patio is constructed at the first location undercontrolled conditions.
 4. A method as in claim 3, wherein the conditionsare controlled by constructing the patio indoors.
 5. A method as inclaim 4, wherein the conditions indoors are controlled for temperature,humidity, or temperature and humidity.
 6. A method as in claim 3,wherein the conditions are controlled by constructing the patio outdoorsbut only under certain weather conditions.
 7. A method as in claim 3,wherein the conditions include controlling a grade of a base on whichthe patio is constructed to be level.
 8. A method as in claim 1, whereinthe step of constructing the patio further comprises the steps of:installing a level base; covering the gravel base with plastic to createa flat level surface; constructing a form on the base; placing a wiremesh on the base inside the form; pouring concrete into the form;allowing the concrete to cure; and adding a sealant to the patio'ssurface.
 9. A method as in claim 8, wherein the step of constructing thepatio further comprises the step of adding one or more colors, surfacepatterns, or colors and surface patterns to the patio.
 10. A method asin claim 1, further comprising the steps of: transporting the sectionsto the second location; and installing the sections at the secondlocation to form the custom patio.
 11. A method as in claim 10, whereinthe step of transporting the sections to the second location furthercomprises the steps of: adding numbers to the sections; stacking thesections separated by a protective material; and transporting thestacked sections.
 12. A method as in claim 11, wherein the step ofinstalling the sections at the second location to form the custom patiofurther comprises the steps of: preparing the second location forinstallation of the patio; and assembling the sections at the secondlocation according to the numbers.
 13. A method as in claim 12, whereinthe second location is prepared to slope away from a structure.
 14. Acustom patio fabricated by constructing at a first location a patiocustomized for a second location, and cutting the patio into sections.15. A patio as in claim 14, wherein the patio is customized for thesecond location in one or more of size, shape, color, and surfacepattern.
 16. A patio as in claim 14, wherein the patio is constructed atthe first location under controlled conditions.
 17. A patio as in claim16, wherein the conditions are controlled by constructing the patioindoors.
 18. A patio as in claim 17, wherein the conditions indoors arecontrolled for temperature, humidity, or temperature and humidity.
 19. Apatio as in claim 16, wherein the conditions are controlled byconstructing the patio outdoors but only under certain weatherconditions.
 20. A patio as in claim 16, wherein the conditions includecontrolling a grade of a base on which the patio is constructed to belevel.
 21. A patio as in claim 14, wherein the patio is furtherfabricated by installing a level gravel base, covering the gravel basewith plastic to create a flat level surface, constructing a form on thebase, placing a wire mesh on the base inside the form, pouring concreteinto the form, allowing the concrete to cure, and adding a sealant tothe patio's surface.
 22. A patio as in claim 21, wherein the patio isfurther fabricated by adding one or more colors, surface patterns, orcolors and surface patterns to the patio.
 23. A patio as in claim 14,wherein the patio is further fabricated by transporting the sections tothe second location, and assembling the sections at the second locationinto the custom patio.
 24. A patio as in claim 23, wherein transportingthe sections to the second location further comprises adding numbers tothe sections, stacking the sections separated by a protective material,and transporting the stacked sections.
 25. A patio as in claim 24,wherein installing the sections at the second location to form thecustom patio further comprises preparing the second location forinstallation of the patio, and assembling the sections at the secondlocation according to the numbers.